ESAB Aristo Retrofit I/O Interface Universal 255 User manual

Category
Welding System
Type
User manual

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ESAB Aristo Retrofit I/O Interface Universal 255 is a device that checks and converts CAN bus signals from a power source to a welding robot. It's compatible with CAN bus-controlled power sources like Mig 4000i or Mig 5000i with U82 I/O. It converts analog and digital signals to field bus communication (CAN) and vice versa.

ESAB Aristo Retrofit I/O Interface Universal 255 is a device that checks and converts CAN bus signals from a power source to a welding robot. It's compatible with CAN bus-controlled power sources like Mig 4000i or Mig 5000i with U82 I/O. It converts analog and digital signals to field bus communication (CAN) and vice versa.

GB
AH 0736c
Valid for serial no. 222-xxx-xxxx0461 314 001 GB 20130531
Aristo
Retrofit I/O Interface
Universal 255
Instruction manual
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TOCe
Rights reserved to alter specifications without notice.
SPARE PARTS LIST 20..................................................
ASSEMBLY INSTRUCTIONS 18...........................................
1 SAFETY 4...........................................................
2 INTRODUCTION 6...................................................
2.1 Equipment 6................................................................
3 TECHNICAL DATA 6.................................................
4 INSTALLATION 6....................................................
4.1 Location 7..................................................................
4.2 Connection instructions 8.....................................................
Others 8.........................................................................
5 OPERATION 9.......................................................
5.1 Connections and control devices 9............................................
6 MAINTENANCE 10....................................................
6.1 Inspection and cleaning 10....................................................
7 FAULT TRACING 10..................................................
8 ORDERING SPARE PARTS 10.........................................
9 CONNECTION & FUNCTION DESCRIPTION OF I/O SIGNALS 11..........
9.1 Connection table for I/O signals on robot side 11.................................
9.2 Input data I/O signals from robot controller to welding equipment 12.................
9.3 Output data I/O signals from the welding equipment to the robot controller 14........
DIAGRAM 16............................................................
ORDER NUMBER 18.....................................................
ACCESSORIES 19.......................................................
© ESAB AB 2013
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1 SAFETY
Users of ESAB equipment have the ultimate responsibility for ensuring that anyone who works on or
near the equipment observes all the relevant safety precautions. Safety precautions must meet the
requirements that apply to this type of equipment. The following recommendations should be
observed in addition to the standard regulations that apply to the workplace.
All work must be carried out by trained personnel well-acquainted with the operation of the
equipment. Incorrect operation of the equipment may lead to hazardous situations which can result
in injury to the operator and damage to the equipment.
1. Anyone who uses the equipment must be familiar with:
S its operation
S location of emergency stops
S its function
S relevant safety precautions
S welding and cutting
2. The operator must ensure that:
S no unauthorised person is stationed within the working area of the equipment when it is
started up.
S no-one is unprotected when the arc is struck
3. The workplace must:
S be suitable for the purpose
S be free from drafts
4. Personal safety equipment
S Always wear recommended personal safety equipment, such as safety glasses, flame-proof
clothing, safety gloves.
S Do not wear loose-fitting items, such as scarves, bracelets, rings, etc., which could become
trapped or cause burns.
5. General precautions
S Make sure the return cable is connected securely.
S Work on high voltage equipment may only be carried out by a qualified electrician.
S Appropriate fire extinquishing equipment must be clearly marked and close at hand.
S Lubrication and maintenance must not be carried out on the equipment during operation.
GB
© ESAB AB 2013
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WARNING
Read and understand the instruction manual before installing or operating.
Arc welding and cutting can be injurious to yourself and others. Take precautions when welding and
cutting. Ask for your employer's safety practices which should be based on manufacturers' hazard
data.
ELECTRIC SHOCK - Can kill
S Install and earth the unit in accordance with applicable standards.
S Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
S Insulate yourself from earth and the workpiece.
S Ensure your working stance is safe.
FUMES AND GASES - Can be dangerous to health
S Keep your head out of the fumes.
S Use ventilation, extraction at the arc, or both, to take fumes and gases away from your breathing zone
and the general area.
ARC RAYS - Can injure eyes and burn skin.
S Protect your eyes and body. Use the correct welding screen and filter lens and wear protective
clothing.
S Protect bystanders with suitable screens or curtains.
FIRE HAZARD
S Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.
NOISE - Excessive noise can damage hearing
S Protect your ears. Use earmuffs or other hearing protection.
S Warn bystanders of the risk.
MALFUNCTION - Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
CAUTION
Read and understand the instruction manual before
installing or operating.
CAUTION
This product is solely intended for arc welding.
Dispose of electronic equipment at the recycling facility!
In observance of European Directive 2002/96/EC on Waste Electrical and Electronic
Equipment and its implementation in accordance with national law, electrical and/or
electronic equipment that has reached the end of its life must be disposed of at a
recycling facility.
As the person responsible for the equipment, it is your responsibility to obtain
information on approved collection stations.
For further information contact the nearest ESAB dealer.
ESAB can provide you with all necessary welding protection and accessories.
GB
© ESAB AB 2013
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2 INTRODUCTION
Retrofit I/O Interface Universal 255 checks and converts the CAN bus signals from
the power source to the welding robot and is used for CAN bus controlled power
sources, such as Mig 4000i or Mig 5000i with U8
2
I/O.
Retrofit I/O Interface Universal 255 converts analogue and digital signals to field
bus communication (CAN) and from field bus signals to digital and analogue signals.
2.1 Equipment
Retrofit I/O Interface Universal 255 is supplied with an instruction manual, control
cable and 48-pol sleeve plug and 0 cable that connects between interface and robot
cabinet.
ESAB can provide you with all necessary welding protection and accessories.
3 TECHNICAL DATA
Retrofit I/O Interface Universal 255
Mains voltage (from robot) 24 V DC
Fuse 1 A
Robot connection 48 pin connection socket
Weight 6.1 kg
Dimensions (l x w x h) 365 x 351 x 110 mm
Enclosure class IP23
Enclosure class
The IP code indicates the enclosure class, i. e. the degree of protection against penetration by solid
objects or water. Equipment marked IP23 is designed for indoor and outdoor use.
4 INSTALLATION
The installation must be carried out by a professional.
CAUTION
This product is intended for industrial use. In a domestic environment this product may
cause radio interference. It is the user's responsibility to take adequate precautions.
WARNING
When welding in an environment with increased electrical danger, only power
sources intended for this environment may be used. These power sources are
marked with the symbol
GB
© ESAB AB 2013
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4.1 Location
Retrofit I/O Interface Universal 255 is installed above the power source. Remove
the rubber mat (C) on the power source and then slide the flange of the interface box
(A) into the side profiles (B) of the power source, see the illustration below.
IMPORTANT! Screw the 3 screws into place on the front of the interface box, tighten
sufficiently hard that electrical connection is made. Check that an electrical
connection has been established.
GB
© ESAB AB 2013
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4.2 Connection instructions
Complete descriptions of the power source / wire feed unit are available in separate
instruction manuals.
1 Connection cables from welding power
source to the wire feed unit.
4 Aristo U8
2
2 CAN bus connection (12 pole Burndy)
from the welding power source to I/O
Interface.
5 Connection between power source unit
and the robot cabinet (potential cable 0V)
3 Control cable between Retrofit I/O
Interface Universal 255 and Robot control
ler
Others
0-cable 6 mm
2
S The 0-cable 6 mm
2
between the power source and the robot cabin is delivered in lengths of
15 m and must be cut to the length required at installation.
Start up time
S The start up time of the Interface box when current/power is activated can be delayed by up
to 1 minute.
GB
© ESAB AB 2013
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5 OPERATION
General safety regulations for handling the equipment can be found on
page 4. Read through before you start using the equipment!
5.1 Connections and control devices
1 Indicator lamp (WHITE), power supply
from robot.
3 Fuse / 1A 24 VDC from robot
2 Connection for signals to/from the robot's
welding gun (48-pol pin socket connector)
4 Connection for torch cleaning station
5 Connection for operating cable from power
source (12-pin CAN bus)
Retrofit I/O Interface Universal 255 is connected to the robot cabinet and the power
source.
The rating plate is located on the
rear side of the Interface box.
GB
© ESAB AB 2013
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6 MAINTENANCE
Regular maintenance is important for safe, reliable operation.
Only those persons who have appropriate electrical knowledge (authorized
personnel) may remove the safety plates.
CAUTION
All guarantee undertakings from the supplier cease to apply if the customer attempts any
work to rectify any faults in the product during the guarantee period.
6.1 Inspection and cleaning
Regularly check that the interface box has electrical connection with the power
source and that the connections are correctly connected and not faulty.
7 FAULT TRACING
S Has the indicator lamp (white) on the front gone out?
Check that the fuse is intact.
S Ensure that the wiring is correctly located in its connectors.
Complete descriptions of the power source, wire feed unit and control panel are available in separate
instruction manuals.
8 ORDERING SPARE PARTS
Repair and electrical work should be performed by an authorised ESAB service
technician. Use only ESAB original spare and wear parts.
Retrofit I/O Interface Universal 255 is designed and tested in accordance with the inter
national and European standards 60974-1 and 60974-10. It is the obligation of the ser
vice unit which has carried out the service or repair work to make sure that the product
still conforms to the said standard.
Spare parts may be ordered through your nearest ESAB dealer, see the last page of
this publication.
* * *
NOTE! 9. CONNECTION AND FUNCTION DESCRIPTION OF I/O SIGNALS
is only available in English and is primarily meant for the integrator and installation of
the Interface box on page 11.
GB
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9 CONNECTION & FUNCTION DESCRIPTION OF I/O SIGNALS
The Retrofit I/O Interface Universal is the interface between the welding robot and the
welding equipment. The Retrofit I/O Interface Universal converts the robot’s I/O signals to
field bus signals to the welding equipment. The Retrofit I/O Interface Universal also
converts the field bus signals from the welding equipment to I/O signals to the welding
robot.
9.1 Connection table for I/O signals on robot side
Connection Cable number
Robot side
I/O Signals
H 8 Weld on
J 9 Gas purge
K 10 Inching wire
L 11 Reverse inching wire
M 12 Air purge
N 13 0V = Quick stop
P 14 analogue active
R 15 Touch sense
S 16 Memory 1
T 17 Memory 2
U 18 Memory 4
V 19 Memory 8
X 21 Memory 16
W 20 Memory 32
Y 22 Memory 64
Z 23 Memory 128
E 5 Voltage reference
F 6 Wirefeed reference
G 7 0V reference to robot
a 24 Arc acknow.
b 25 Touch sense resp.
c 26 0V = Machine error
d 27 Collision detect
e 28 Weld busy
f 29 Remote active
A 1 24V supply from robot
B 2 0V supply from robot
Shield Shield Ground
v 30 G-Stop
u 31 G-Stop
p 32 G-Stop
q 33 G-Stop
g 34 Lubrication
h 35 Lubrication cleaning
i 36 Lubrication finish
Input
Output
Power
General
Torch
Analogue
supply
Equipment
Equipment
cleaning
Input
stop
Equipment
Welding
Welding
Welding
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9.2 Input data I/O signals from robot controller to welding
equipment
Weld ON (Cable no 8)
The signal starts the welding process, but before the welding process starts the
quick stop and stop signals are checked to ensure that they are not active.
Quick stop (Cable no 13)
The signal stops the equipment if it is active in the welding process, it carries out a
normal stop without crater filling. The function is used when a quick stop (low signal
0V) is required but it gives a normal burnback time to prevent the wire sticking in the
weld pool. The signal also blocks the start command.
Wire inching (Cable no 10)
Used when one wants to feed wire without welding voltage.
The signal starts the wire feed without the welding voltage being activated. The wire
feed unit is ramping up the wire feed speed. If the signal is active during the welding
process, the command is ignored.
If both welding and wire inching are activated at the same time the equipment will
ignore the wire inching command and start the welding process.
Gas purge (Cable no 9)
Gas flushing is used when measuring the gas flow or to flush any air or moisture
from the gas hoses before welding starts. Gas flushing is carried out without voltage
or wire feed occurring.
Welding start always activates the gas valve even if the manual gas command is
given. In the same way the gas valve for gas post flow is always closed if it is not
closed already.
Gas flushing operates parallel to the gas preflow and gas postflow functions. To
control the welding gas from the robot, set the gas preflow to minimum and the gas
postflow to maximum, and then control the welding gas using the gas flushing
functions.
Air purge (Cable no 12)
The signal controls the valve for air cleaning welding spatter.
Touch sense (Cable no 15)
This command is used by the robot to sense where the wire is.
When the function is active, the power source will give out current limited, idle
voltage to see if the wire is in contact with the workpiece. On contact, the output
signal Touch sense response is activated.
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Analogue Active (Not availabe for the moment)
The signal is used to switch between the analogue and digital remote modes.
Analogue Active allows analogue control of the welding parameters, voltage, arc
voltage and the wire feed speed.
If the welding method SuperPulse is to be used, the analogue active signal must be
deactivated.
When the analogue method is activated the power source will not use the preset
values for wire feed speed and voltage when new welding data is selected. When
analogue active is activated the robot controls arc voltage and wire feed speed
using analogue signals.
With the analogue active signal deactivated, welding data is exchanged with preset
welding data such as voltage, wire feed speed to fixed set welding parameters.
The preprogrammed welding data (schedules) is requested from the control box
U8
2
welding data memory.
Welding data (Memory) (Cable 16-23)
With the signals memory 1, 2, 4, 8, 15, 32, 64, 128 one accesses saved welding data
(schedules) in U8
2
I/O.
The binary coded combinations of these signals can be used to recall the memories
1255 in the U8
2
I/O memory bank.
A complete set of welding data includes all settings that can be made in U8
2
I/O, see
the instruction manual for U8
2
.
Voltage reference (Cable no 5 - Not available at the moment)
This signal is used by the robot for analogue control of the welding voltage if
analogue active is selected. It stretches from 010V and corresponds to welding
voltage socket as follows.
0V reference gives a deviation on the selected arc voltage of 10V
10V reference gives a deviation on the selected arc voltage of +10V
If the machine is in nonsynergy mode, the equipment will use the appreciated
value.
0V reference gives arc voltage 8V
10V reference gives arc voltage 60V
Wire feed speed reference signal (Cable no 6 - Not available at the moment)
The signal is used by the robot to make analogue adjustments to the wire feed
speed. The internal solution is 0.1 m/min.
Input voltage
0 V Mini. value for wire feed (normally 0.8 m/min) (RoboFeed)
10 V Max. value for wire feed (normally 30 m /min)
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9.3 Output data I/O signals from the welding equipment to the
robot controller
Arc acknowledge (Cable no 25)
The signal is activated after established welding start if the voltage and current
strength lie within weldable limits. The signal disappears if welding cannot be
established.
The criterion for establishing a welding arc is that the process control has passed the
start procedure, which means that only a short circuit is not sufficient to meet the
criteria. Normal delay from the first contact, which is acknowledged by the welding
arc (wire feed time for this after the first contact is established ) is in the range of 2 to
20 ms. If there is a poor start to the welding arc the Arc acknowledge is further
delayed.
Touch sense response (Cable no 26)
This signal indicates contact in the welding circuit, i.e. that the wire is in contact with
the workpiece. To obtain touch sense response the touch sense input signal must
be activated.
Collision detect (Cable no 26)
The signal comes via the internal CAN bus from the feeding mechanism (RoboFeed).
The signal indicates that the robot’s breaker has activated. The interface activates a
relay which breaks two safety loops from the robot, at which the robot orders a quick
stop of both robot and the welding equipment.
The output is high when the welding gun breaker is tripped (the signal is sent to the
robot).
Machine error (Cable no 27)
The signal is low (0V) when an error has been detected in the welding equipment.
Weld busy (Cable no 28)
This signal indicates when the welding equipment is occupied with welding. The
signal can be configurated in the U82 I/O configuration menu.
Remote active (Cable no 29)
Remote active is activated when remote is chosen in U8
2
.
General stop (Cable no 30-33)
Can be used as an electrical stop, to stop the servo motors on the robot, when
collision detect signal is low (0V).
© ESAB AB 2013
Diagram
Com 0V
Com 0V
Wire 0-10V
Voltage 0-10V
0V
CAN HIGH
CAN LOW
24VR
0VR
24VR
0VR
Reserve
Reserve
Remote Active
Weld Busy
Filter board 1
Digital output from
equipment
Bus
resistor
External General Stop
Torch cleaner
C1
D
XS04
24VR
E
0VR
C B A
X1
X2
HL1
024023
3
4
R2
026025
5
6
A1
A2
R1
414
154
KL3062
101
603
102
505
103
401
XP01
A
X5
3
X5
1 2
B K L E G
i
XS03
h g G F E
45
J4
6
J1
1 2 3
53 17
KL9010
Power source
A
XS01
B K L E G
4
XP03
i h g v u p q
v u p q
224 223 221
222114
201
A1
A2
R2
022
G F E
W1
33323130
567
343536
KL2134:2
14 583276
612
711
815
27
d
d
315
613
712
415
615
614
714
713
X6
1 2 3 4
616
715
X7
1
2
Analog input
to equipment
Interface Box
Not available at the moment
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© ESAB AB 2013
24VR
0VR
24VR
0VR
Collision Detect
Machine Error=0V
Tourch Sense R.
Arc Acknowledge
Memory 8
Memory 4
Memory 2
Memory 1
Wire Feeder
Reserve
Reserve
Tourche Sense
Reserv
Analog Active
Quick Stop
Air Purque
Reverse Wire
Inching
Gas Purge
Weld On
0V
CAN LOW
CAN HIGH
Memory 128
Memory 64
Memory 32
Memory 16
Reserve
Reserve
Reserve
Reserve
Filter board 2
Filter board 1
Digital input to
equipment
Digital input to
equipment
Digital input to
equipment
Digital output from
equipment
Robot
AP1
KL2134:1
104
304
105205
106
1001
KL1408:2
001
1808
002
1704
003
1607
004
1503
008
1101
KL1408:1
111
3
4
R1
011807
012
703
014
502
015405
016
301
BK5151
017
200
218
A1
A2
FU1
1A
018
124
c b a V U T S R N M K J H B A
123
J5
18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3
J6
2 1
4 5 6
J2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
J3
2 1
-+
24
V
0
V
12 56374812 56374814 583276
W2
4 3 1
Interface Box
7 2 3
N M K J H B Ac b a V U T S R
16171819
242526
606
904
15
13 12 10 9
8
2
1
14
11
LP
LP
010
013
28
e
e
29
f
f
005
1405
220302
12 563748
KL1408:3
AP1
AP2
J2
1
5
1
6
1
7
1
8
J5
4 3 2 1
Z Y X
Z Y X
212223 20
W
W
1504
1603
1701
1801
1806
1702
1605
1501
202
203
Shield
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br08dia
Retrofit I/O Interface Universal 255
© ESAB AB 2013
Order number
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br08o
Ordering no. Denomination Notes
0461 090 884 Retrofit I/O Interface Universal 255 Includes the Control cables, see on
page 18 and a Instruction manual.
0461 314 001 Instruction manual Retrofit I/O Interface Universal 255
0459 839 091 Spare parts list Retrofit I/O Interface Universal 255
Retrofit I/O Interface Universal 255
© ESAB AB 2013
Accessories
- 18 -
br08acc
Aristo
[
U8
2+
I/O ........................... 0460 820 883
Rebuilding kit Incl. Adapter (12 pole to 10 pole) .
Mig 4002, 5002 and 6502
0461 322 880
Extension cable (U8
2
, 7,5 m) ................. 0460 877 891
Control cable
Retrofit I/O to power source (1,7 m) ........... 0461 319 880 *
Control cable (7,5 m, 48-pole) ................. 0461 321 880
* Included in 0461 090 884 Retrofit I/O Interface Universal 255
www.esab.com
110915© ESAB AB
ESAB subsidiaries and representative offices
Europe
AUSTRIA
ESAB Ges.m.b.H
Vienna-Liesing
Tel: +43 1 888 25 11
Fax: +43 1 888 25 11 85
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Heist-op-den-Berg
Tel: +32 70 233 075
Fax: +32 15 257 944
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ESAB Kft Representative Office
Sofia
Tel/Fax: +359 2 974 42 88
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Vamberk
Tel: +420 2 819 40 885
Fax: +420 2 819 40 120
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Tel: +45 36 30 01 11
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Tel: +358 9 547 761
Fax: +358 9 547 77 71
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Tel: +33 1 30 75 55 00
Fax: +33 1 30 75 55 24
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Tel: +49 212 298 0
Fax: +49 212 298 218
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Tel: +44 1992 76 85 15
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Fax: +44 1264 33 20 74
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Tel: +31 33 422 35 55
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AS ESAB
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Tel: +47 33 12 10 00
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Tel: +34 91 878 3600
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Tel: +46 31 50 95 00
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Tel: +54 11 4 753 4039
Fax: +54 11 4 753 6313
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ESAB S.A.
Contagem-MG
Tel: +55 31 2191 4333
Fax: +55 31 2191 4440
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ESAB Group Canada Inc.
Missisauga, Ontario
Tel: +1 905 670 02 20
Fax: +1 905 670 48 79
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Tel: +52 8 350 5959
Fax: +52 8 350 7554
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Tel: +1 843 669 44 11
Fax: +1 843 664 57 48
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AUSTRALIA
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Archerfield BC QLD 4108
Tel: +61 1300 372 228
Fax: +61 7 3711 2328
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Shanghai
Tel: +86 21 2326 3000
Fax: +86 21 6566 6622
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Calcutta
Tel: +91 33 478 45 17
Fax: +91 33 468 18 80
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Fax: +62 21 461 2929
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Tel: +81 45 670 7073
Fax: +81 45 670 7001
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USJ
Tel: +603 8023 7835
Fax: +603 8023 0225
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Tel: +65 6861 43 22
Fax: +65 6861 31 95
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Fax: +82 55 289 8864
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Tel: +971 4 887 21 11
Fax: +971 4 887 22 63
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Tel: +20 2 390 96 69
Fax: +20 2 393 32 13
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Durbanvill 7570 - Cape Town
Tel: +27 (0)21 975 8924
Distributors
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ESAB Aristo Retrofit I/O Interface Universal 255 User manual

Category
Welding System
Type
User manual
This manual is also suitable for

ESAB Aristo Retrofit I/O Interface Universal 255 is a device that checks and converts CAN bus signals from a power source to a welding robot. It's compatible with CAN bus-controlled power sources like Mig 4000i or Mig 5000i with U82 I/O. It converts analog and digital signals to field bus communication (CAN) and vice versa.

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